I'm trying to help a friend with his 220 Bayou. He let someone borrow it and when they brought it back it was nice and clean and in his garage. Six months later he went to use it and it turned over then locked up. Tried a new battery, checked starter and tried to pull start it. Still locked up. So far I have drained the oil and pulled the filter checked for metal, nothing there. Then I pulled the generator cover to check the starter gears and found metal everywhere. Now the engine will turn by hand with the spark plug out, but it is still tight. It seems to have good compression. Where did the metal shaving come from? What do I check next?

 

As you may know, the baby Bayous have a "plastic" oil pump drive gear. When inexperienced rider uses high gears when going slow, the semi-auto clutch develops a tremendous amount of heat in the transmission area. The heat kills almost everthing inside the engine, the plastic part first. When the plastic oil pump drive gear melts/breaks, no more oil circulation. In order to inspect it, remove the primary clutch housing with the hub, the recoil starter and balancer gear nut on the righ hand side of the engine. You will need a some kind of holder to hold the primary and secondary gear to remove the primary and secondary clutch hub nuts.
Hope the problem is something else...

 

It turned out to be the bolts on the one way clutch had backed out. It sheared one off and locked up the starter gear. Not near as bad as I thought it would be. Thanks for your help, maybe I can return the favor.